Apparatus and methods for resizing electronic displays

Abstract

Apparatus and methods for resizing COTS AMLCDs or other electronic displays, as well as resized displays made using these apparatus and methods, are provided. The electronic display includes a front plate, a back plate, a perimeter seal spacing the front and back plates apart, and image-generating medium contained in an area between the front and back plates. A target portion of the display may be identified and separated from an excess portion of the display, e.g., by cutting and breaking the plates of the display, thereby creating an exposed edge along the target portion. The plates of the target portion are pressed towards one another, e.g., to stabilize or compress the target portion. An adhesive is applied to the exposed edge, and the pressure is released to draw the adhesive between the plates along the exposed edge.

1. A method for resizing an electronic display, the display comprising a front plate, a back plate, a perimeter seal spacing the front and back plates apart, and image-generating medium contained in an area between the front and back plates and within the borders of the perimeter seal, the front and back plates being spaced apart by a predetermined cell gap, the method comprising:
 creating a scribe line along each of the front and back plates to identify a target portion and an excess portion of the display; 
 breaking the display along the scribe lines to separate the target and excess portions of the display, thereby creating an exposed edge along the target portion communicating with the area between the plates of the target portion; 
 mounting the target portion between pressure plates of a fixture with the exposed edge protruding from an edge of the fixture, at least one of the pressure plates comprising a bladder; 
 increasing pressure within the bladder by about one to three psi to press the plates of the target portion towards one another, thereby causing image-generating material to be forced out along the exposed edge; 
 applying adhesive along the exposed edge; and 
 decreasing the pressure within the bladder to return the plates of the target portion to the predetermined cell gap, thereby drawing the adhesive between the plates along the exposed edge. 
 
     
     
       2. The method of  claim 1 , further comprising curing the adhesive after the plates of the target portion are returned to the predetermined cell gap, thereby creating a first seal between the plates along the exposed edge, the first seal creating a barrier to prevent the image-generating medium from escaping out of the area between the plates of the target portion. 
     
     
       3. The method of  claim 2 , wherein the adhesive is cured by exposing the adhesive to ultraviolet light. 
     
     
       4. The method of  claim 1 , further comprising removing image-generating material that is forced out along the exposed edge when the plates of the target portion are pressed towards one another. 
     
     
       5. The method of  claim 4 , wherein the image-generating medium is removed before the adhesive is applied along the exposed edge. 
     
     
       6. The method of  claim 1 , wherein the target portion of the display is mounted within the fixture before the display is broken. 
     
     
       7. The method of  claim 1 , wherein the target portion of the display is mounted to a first of the pressure plates, and wherein a second of the pressure plates is mounted to the first of the pressure plates at a predetermined spacing. 
     
     
       8. The method of  claim 1 , wherein the target portion of the display is mounted between the pair of pressure plates by inflating the bladder to a first pressure for maintaining the plates of the target portion at the predetermined cell gap, wherein the plates of the target portion are pressed towards one another by inflating the bladder to a second pressure greater than the first pressure, and wherein the plates of the target portion are returned to the predetermined cell gap by deflating the bladder to a third pressure less than the second pressure. 
     
     
       9. The method of  claim 1 , wherein the adhesive is applied along the exposed edge without removing image-generating material forced out along the exposed edge. 
     
     
       10. The method of  claim 1 , further comprising removing image-generating material that is forced out along the exposed edge. 
     
     
       11. The method of  claim 10 , wherein the image-generating medium is removed before the adhesive is applied along the exposed edge. 
     
     
       12. The method of  claim 1 , wherein the display is broken by placing a strip along the at least one scribe line, and directing material along the at least one scribe line to cause the front and back plates to break along the at least one scribe line. 
     
     
       13. The method of  claim 1 , wherein breaking the display comprises:
 placing the display on a flat plate with the back plate adjacent the flat plate; 
 applying pressure to the display to cause the back plate to break along the scribe line; 
 turning the display over so that the front plate is adjacent the flat plate; and 
 applying pressure to the display to cause the front plate to break along the scribe line, thereby separating the target and excess portions and creating the exposed edge. 
 
     
     
       14. A method for resizing an electronic display, the display comprising a front plate, a back plate, a perimeter seal spacing the front and back plates apart, and image-generating medium contained in an area between the front and back plates and within the borders of the perimeter seal, the front and back plates being spaced apart by a predetermined cell gap, the method comprising:
 creating a scribe line along each of the front and back plates to identify a target portion and an excess portion of the display; 
 placing the display on a flat plate with the back plate adjacent the flat plate; 
 applying pressure to the display to cause the back plate to break along the scribe line; 
 turning the display over so that the front plate is adjacent the flat plate; 
 applying pressure to the display to cause the front plate to break along the scribe line, thereby separating the target and excess portions and creating an exposed edge along the target portion communicating with the area between the plates of the target portion; 
 placing the target portion between pressure plates of a fixture with the exposed edge protruding from one edge of the fixture, at least one of the pressure plates comprising a bladder; 
 inflating the bladder to press the front and back plates of the target portion towards one another, thereby causing image-generating material to be forced out along the exposed edge; 
 applying adhesive along the exposed edge; 
 at least partially deflating the bladder, thereby drawing the adhesive between the plates along the exposed edge and returning the plates of the target portion to the predetermined cell gap; and 
 curing the adhesive after the plates of the target portion are returned to the predetermined cell gap, thereby creating a first seal between the plates along the exposed edge, the first seal creating a barrier to prevent the image-generating medium from escaping out of the area between the plates of the target portion. 
 
     
     
       15. The method of  claim 14 , wherein the adhesive is cured by exposing the adhesive to ultraviolet light. 
     
     
       16. The method of  claim 14 , further comprising:
 inflating the bladder to a first predetermined pressure after the target portion is placed between the pressure plates to return the plates of the target portion to the predetermined cell gap, and 
 wherein the bladder is inflated to a second predetermined pressure greater than the first predetermined pressure to press the front and back plates of the target portion towards one another. 
 
     
     
       17. The method of  claim 16 , wherein the first predetermined pressure is approximately two pounds per square inch (2 psi). 
     
     
       18. The method of  claim 16 , wherein the second predetermined pressure is about one to three psi greater than the first predetermined pressure. 
     
     
       19. The method of  claim 16 , wherein the bladder is deflated to a third predetermined pressure less than the second predetermined pressure. 
     
     
       20. The method of  claim 14 , wherein the adhesive is applied along the exposed edge without removing image-generating material forced out along the exposed edge. 
     
     
       21. The method of  claim 14 , further comprising removing image-generating material that is forced out along the exposed edge. 
     
     
       22. The method of  claim 21 , wherein the image-generating medium is removed before the adhesive is applied along the exposed edge.